Document Type : Research Paper


1 Ph.D. Student, School of Chemical Engineering, College of Engineering, University of Tehran, Tehran, Iran

2 M.S. Student, School of Chemical Engineering, College of Engineering, University of Tehran, Tehran, Iran

3 Professor, School of Chemical Engineering and Institute of LNG, College of Engineering, University of Tehran, Tehran, Iran Highlights



Today, one of the challenging issues all over the world is the appropriate use of flare gases in oil, gas, and petrochemical industries. Burning flare gases having high heating value results in economic losses and the pollution of the environment. There are several methods to use flare gases; the heat and power generation, the production of valuable fuels, or the separation of more precious components are examples of these methods. In this study, a polygeneration system is designed and simulated for the coproduction of power, steam, methanol, H2, and CO2 from the flare gases in South Pars and Assaluyeh gas fields. The polygeneration system has advantages such as reducing greenhouse gases and the coproduction and sales of energy-related products. The polygeneration system for converting flare gases to energy and various products includes an acid gas removal unit, a synthesis gas production unit, a methanol synthesis unit, a hydrogen purification unit, a combined heat and power generation unit, and a CO2 capture unit. The purpose of this study is to conduct an economic evaluation of the polygeneration system and obtain the total capital cost, the operating profit, and the payback period of this process. The simulation results show that using 9690 kg/h of flare gases produces 8133 kg/h methanol, 653.7 kg/h hydrogen, 46950 kg/h nitrogen, 9103 kg/h CO2, 109850 kg/h medium-pressure steam, and 3.7 MW power. The economic evaluation results show that in the polygeneration system, the total raw material cost and the total utilities consumption cost are $193.8 and $1859.5 per hour respectively, and the total product sales and the total utility sales are $12941.8 and $2243.5 per hour respectively; also, the operating profit is $13132 per hour. Also, the equipment cost, the installation cost, the total capital cost, and the total operating cost are $29.7 million per year, $39.2 million per year, $71 million per year, and $27.9 million per year respectively; finally, the payback period is 1.5 years.


  • The polygeneration system has been used for converting flare gas to energy and various products such as power, steam, methanol, H2, and CO2;
  • A polygeneration system has lower raw material cost, utility cost, and operating cost than the corresponding single-product processes;
  • The total capital cost and the operating profit of the polygeneration system are $71 million and $115 million per year respectively, and the payback period is 1.5 years.


Main Subjects

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